Vehicle trim component

ABSTRACT

A vehicle trim component is disclosed. A method for forming the trim component is also disclosed. The trim component is configured to support an airbag chute providing an airbag. The airbag is configured to be deployed through an opening. The trim component may comprise (a) a substrate a structure, (b) a cover comprising a skin made of a thermoplastic material (e.g. TPO having a substantially constant thickness of less than 0.7 mm) and a support layer coupled to the skin, and (c) a thermoplastic (e.g. foam) layer between the cover and the substrate. The thermoplastic foam) layer may be configured to attach the cover to the substrate. The airbag chute may be secured between the thermoplastic (e.g. foam) layer and the substrate. The support layer may be made of a foam material (e.g. polypropylene and/or polyethylene foam). The process for forming the trim component may comprise the steps of (a) providing a skin; (b) applying a support layer to the skin to create a cover; (c) providing the cover in a mold; (d) providing an airbag chute in the mold; (e) providing a substrate in the mold; and (I) injecting a thermoplastic (e.g. foam) material between the cover and the substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation in part of International Application No. PCT/US15/032624 titled “VEHICLE INTERIOR PANEL AND METHOD OF MANUFACTURE” filed May 27, 2015.

The present application claims priority from and the benefit of and incorporates by reference in entirety of the following applications: (a) International Application No. PCT/US15/032624 titled “VEHICLE INTERIOR PANEL AND METHOD OF MANUFACTURE” filed May 27, 2015; (b) U.S. Provisional Patent Application No. 62/003,332 titled “BACKING ON THIN TPO FOR HANDLING ISSUES” filed May 27, 2014.

FIELD

The present invention relates to a trim component for a vehicle interior.

BACKGROUND

It is known to provide a trim component for vehicle interior. It is also known to provide airbags within the vehicle interior to facilitate protection of vehicle occupants during a collision. It is also known to place an airbag within a chute behind the surface of a trim panel within a vehicle interior. It is also known to provide a weakened area (such as a score line) in the trim panel to facilitate deployment of an airbag through an opening (e.g. at the score line) in the trim panel into the vehicle interior to provide protection during a collision.

It would be advantageous to provide an improved trim component for a vehicle interior to facilitate deployment of an airbag.

SUMMARY

The present invention relates to a trim component for a vehicle interior configured to provide an opening for deployment of an airbag from a chute through the opening. The component may comprise a substrate providing a structure, a cover comprising a skin layer and a support layer coupled to the skin layer and a core layer configured to attach the cover to the substrate. The skin layer may comprise a thermoplastic material (e.g. thermoplastic olefin material) provided in a generally uniform thickness less than 0.7 mm. The support layer may be provided in a thickness in a range between 1 mm and 4 mm. The chute may be secured between the core layer and the substrate. The core layer may comprise a foam layer; the foam layer may be formed from a foam material applied as a liquid configured to attach the cover to the substrate; the foam layer may comprises a foam material provided in a thickness in a range between 3 and 15 mm. The core layer may comprise a foam material provided to solidify to attach the cover to the substrate. The support layer may have a density between 3 and 7 pounds per cubic foot; the support layer may be configured to at least partially prevent deformation of the skin layer when force is applied to the cover; deformation may comprise at least one of (a) stretching or (b) elongating. The skin layer may be provided without a localized area of reduced thickness. The substrate may comprise a notch configured to facilitate deployment of the airbag through the opening by facilitating formation of the opening through the core layer and support layer and skin layer.

The present invention relates to a trim component for a vehicle interior configured to provide an opening for deployment of an airbag from a chute through the opening prepared by a process using a mold. The component may comprise the steps of providing a skin layer, applying a support layer to the skin layer to form a cover, providing the cover in the mold, providing the chute in the mold, providing a substrate in the mold and injecting a thermoplastic material between the cover and the substrate. The thermoplastic material may attach the cover and the substrate. The cover may comprise a skin layer of a generally uniform thickness of less than 0.7 mm. The thermoplastic material may comprises a foam material; the process may comprise the step of the foam material solidifying to attach the cover to the substrate. The skin layer may comprise a thermoplastic olefin material. The support layer may comprise a foam comprising polypropylene and polyethylene with a density between 3 and 7 pounds per cubic foot and a thickness in a range between 1 and 4 mm.

The present invention relates to a process using a mold for forming a trim component for a vehicle interior configured to provide an opening for deployment of an airbag from a chute through the opening. The component may comprise the steps of providing a skin layer as a sheet made of a thermoplastic material having a substantially uniform thickness less than 0.7 mm, applying a support layer to the skin layer to form a cover, providing the cover in the mold, providing the chute in the mold, providing a substrate in the mold, injecting a thermoplastic material between the cover and the substrate and solidifying the thermoplastic material to form a cover layer to attach the cover to the substrate. The thermoplastic material may comprise a foam material. The core layer may comprise a foam layer; solidifying the foam material may comprise at least one of (a) hardening or (b) curing. The skin layer may be provided as a substantially uniform layer without a localized area of reduced thickness. The method may also comprise the step of securing the chute between the thermoplastic material and the substrate. Applying the support layer to the skin layer to form the cover may comprise laminating the support layer to the skin layer. The method may also comprise providing a first gap between the cover and the chute and providing a second gap between the cover and the substrate; the thermoplastic material may be injected to fill the first gap and to fill the second gap to form the core layer.

The present invention relates to a vehicle trim component configured to support an airbag chute providing an airbag configured to be deployed through an opening. The component comprises a substrate providing support for the trim component, a cover (e.g. outer layer) comprising a skin made of a thermoplastic olefin material having a substantially constant thickness less than 0.7 mm and a support layer coupled to the skin and foam layer located between the outer layer and the substrate. The foam layer attaches the outer layer to the substrate. The airbag chute may be secured between the foam layer and the substrate; the foam layer may be comprised of a liquid foam material configured to harden or cure to attach the outer layer to the substrate. The support layer may be made of a polypropylene and/or polyethylene foam; the support layer may have a density between 3 pounds per cubic foot and 7 pounds per cubic foot and a thickness between 1 mm and 4 mm. The support layer may be configured to prevent the outer layer from stretching or elongating in response to an applied force to the outer layer. The skin does not include a localized area of reduced thickness. The airbag chute may comprise a localized area of reduced thickness.

The present invention also relates to a vehicle trim component prepared by a process. The process comprises providing a skin, applying a support layer to the skin to create an outer layer, providing the outer layer in a mold, providing an airbag chute in the mold, providing a substrate in the mold and injecting a foam material between the outer layer and the substrate. The process may comprise the foam material attaching the outer layer to the substrate; the process may comprise securing the airbag chute between the foam material and the substrate. The skin may comprise a thermoplastic olefin material having a substantially constant thickness less than 0.7 mm. The support layer may comprise a polypropylene and/or polyethylene foam having a density between 3 pounds per cubic foot and 7 pounds per cubic foot and a thickness between 1 mm and 4 mm.

The present invention also relates to a method of manufacturing an interior panel for a vehicle. The method may comprise providing a skin made of a thermoplastic olefin material having a substantially constant thickness less than 0.7 mm, applying a support layer to the skin to create an outer layer, providing the outer layer in a mold, providing an airbag chute in the mold, providing a substrate in the mold and injecting a foam material between the outer layer and the substrate. The method also comprises hardening or curing the foam material to attach the outer layer to the substrate, removing the interior panel from the mold after the foam material cures, wherein no further steps are taken to introduce a localized area of reduced thickness to the skin and securing the airbag chute between the foam material and the substrate. The airbag chute may comprise a localized area of reduced thickness. Applying the support layer to the skin may comprise laminating the support layer to the skin. The method may also comprise providing a first gap between the outer layer and the airbag chute and providing a second gap between the outer layer and the substrate wherein the first gap and the second gap are configured to receive the foam material.

The present invention relates to an interior panel for use in a vehicle including a rigid substrate providing structural support for the interior panel, an outer layer made of a thermoplastic olefin material having a substantially constant thickness less than about 0.7 mm, and a foam layer located between the outer layer and the substrate.

The present invention relates to a method of manufacturing an interior panel for a vehicle. The method includes providing an outer layer made of a thermoplastic olefin material having a substantially constant thickness less than about 0.7 mm, applying a support layer to the outer layer to create a reinforced, multi-layer structure, positioning the multi-layer structure within a mold, and injecting a foam material adjacent the multi-layer structure.

Other features and aspects of the inventions will become apparent by consideration of the description and drawings.

FIGURES

FIG. 1A is a schematic perspective view of a vehicle according to an exemplary embodiment.

FIG. 1B is a schematic perspective view of an instrument panel for vehicle interior according to an exemplary embodiment.

FIG. 2A is a schematic cross-section exploded view of a multi-layer structure or cover according to an exemplary embodiment.

FIG. 2B is a schematic cross-section view of the multi-layer structure or cover according to an exemplary embodiment.

FIGS. 2C through 2F are schematic diagrams of a process of making a component for a vehicle interior according to an exemplary embodiment.

FIG. 2G is a schematic cross-section view of the component with substrate and cover and chute with airbag module according to an exemplary embodiment.

FIGS. 3A through 3C are schematic flow diagrams of a process for making a component for a vehicle interior according to an exemplary embodiment.

FIGS. 4A through 4C are schematic cross-section views of airbag deployment from the component according to an exemplary embodiment.

FIG. 5A through 5D are schematic perspective views of airbag deployment from the component according to an exemplary embodiment.

FIG. 6 is a schematic cross-section view of a generally conventional interior panel arrangement with an airbag chute.

DESCRIPTION

Referring to FIG. 1A as shown schematically, a vehicle V provides a turn component shown as a panel such as an instrument panel IP within a vehicle interior according to an exemplary embodiment.

As shown schematically in FIG. 1B, the trim component or panel 10 provides an outer surface (e.g. exterior surface) provided by a layer shown as skin 18 (e.g. of cover or outer layer of component); according to an exemplary embodiment the panel 10 provides a cover or an outer layer such as skin 18 through which an airbag A may be deployed as shown schematically in FIGS. 4A-4C and 5A-5D.

As shown schematically in FIGS. 2A and 2B, skin 18 and a support layer 30 may form a bi-laminate or multi-layer structure shown as cover 50 (e.g. outer surface/layer) for the trim component. See also FIGS. 2G and 5A. As shown schematically in FIG. 2B according to an exemplary embodiment, skin 18 is reinforced by a support layer 30 to form cover 50 for the panel. See also FIGS. 5A-5D. According to an exemplary embodiment, the support layer 30 is provided (e.g. attached, applied, etc.) for the outer skin 18 as reinforcement;

As shown schematically according to an exemplary embodiment in FIGS. 2A-2B, 2C and 2F, the process to manufacture the panel 10 comprises forming a reinforced multi-layer structure shown as cover 50 by applying the support layer 30 to the outer skin 18. According to an exemplary embodiment, a laminating process to form the cover 50 may be used to apply the support layer 30 to the outer skin 18. According to an exemplary embodiment, the cover 50 (e.g. multi-layer structure) may be positioned within a mold. According to an exemplary embodiment, in cover 50 the outer layer or skin 18 is reinforced by the support layer 30 and may be transported to the mold with reduced potential for damage during transport; the support layer 30 may also function to reduce or substantially prevent of wrinkling and bunching of the skin 18 during the foam injection process. See FIGS. 2C-2F. (According to an exemplary embodiment, the outer skin 18 may be provided in a thickness substantially less than the thickness of a conventional skin for a conventional trim panel such as shown schematically in FIG. 6.)

As shown schematically according to an exemplary embodiment in FIGS. 2C to 2F, the cover 50 (e.g. multi-layer structure) is positioned within the mold with the rigid substrate 14 and the airbag chute 44 in a spaced relation providing a gap G between the substrate 14 and the chute 44.

As shown schematically according to an exemplary embodiment in FIGS. 2C to 2F, a foam material F (e.g. liquid) is injected in the gap (e.g. through port P in the mold comprising mold top section MT and mold bottom section MB); the material F is allowed to harden or cure to create the core shown as foam layer 34; the foam material is configured to attach the cover 50 to the rigid substrate 14 and chute 44 (e.g. a surface 28). As shown schematically in FIGS. 2C-2F and 2G, the chute 44 is secured or captured (e.g. entrapped) between the foam layer 34 and the substrate (e.g. rigid structure) 14. According to an exemplary embodiment, the chute 44 is formed into a structure with cover 50 and substrate 14. See FIGS. 2G and 4A. According to an exemplary embodiment, after formation of the core or foam layer 34 (e.g. foam material F has been solidified or cured) the formed panel 10 can be removed from the mold. See FIGS. 2F and 2G. According to an exemplary embodiment, the airbag module AM is installed to the airbag chute 44 before or upon the assembly of the panel 10. According to an exemplary embodiment as indicated schematically in FIGS. 2C-2G, no localized area of reduced thickness such as scoring (or otherwise cutting the inner surface 26 of the skin 18) is required; the skin 18 is sufficiently thin to permit the airbag A to create and deploy through an opening.

As shown schematically according to an exemplary embodiment in FIG. 2G, the substrate 14 includes internal sidewalls 38 of an open section or mounting 42 (e.g. for a chute) through which an airbag A may be deployed (as shown in FIGS. 4A to 4C). According to an exemplary embodiment, chute 44 is provided in the space of open section 42 provided in substrate 14. An airbag module AM (in which the airbag A is contained) is installed in the chute 44; chute 44 is formed (e.g. molded) with a localized area of reduced thickness (i.e. pre-weakened area shown as a notch 48) to facilitate deployment of airbag A (e.g. successful deployment through the notch or pre-weakened area 48). See FIGS. 2G, 4A-4C and 5A-5D.

As shown schematically in FIGS. 4A to 4C and 5A to 5D, the airbag A is deployed through the interior panel 10 according to an exemplary embodiment. As shown schematically in FIG. 4A, the airbag A is deployed from the module AM and begins to expand behind the interior panel 10 at the airbag chute 44 (e.g. rupturing to begin to establish an opening) and causing the foam layer 34 and the structure 50 to bulge outward. See also FIG. 5B. As shown schematically in FIGS. 4B and 4C, the airbag A continues to expand (e.g. to establish the opening for deployment); the airbag A breaks through the foam layer 34 and the structure 50 (e.g. cover) (see also FIGS. 5B and 5C) and the airbag A deploys into the vehicle interior (e.g. passenger compartment). See e.g. FIG. 5D (indicating full deployment as shown schematically).

According to an exemplary embodiment, the skin 18 is made of a thermoplastic olefin (TPO) material; the skin 18 is provided in a thickness that facilitates deployment of an airbag A through the skin 18 (e.g. as shown without pre-weakened areas such as scores, cuts, etc.). See FIGS. 2G and 5A-5D, compare FIG. 6 (indicating a generally conventional arrangement for panel 110 provided with extended cut 150 including into outer skin 118). According to an exemplary embodiment, skin 18 is provided in a thickness of between about 0.3 mm and about 0.7 mm, such as approximately 0.5 mm and less than about 0.7 mm (i.e. may be provided in a generally uniform thickness, in a range of thickness, etc.). See FIGS. 2A-2B, 2G and 4A-4C. According to an exemplary embodiment, the support layer 30 is made of a foam material (e.g. polypropylene and/or polyethylene); according to an exemplary embodiment, the support layer may be made of or include various other suitable materials. According to an exemplary embodiment, the support layer 30 is provided in a thickness of about 1 mm to about 4 mm, such as about 1.5 mm. According to an exemplary embodiment, the foam used to create the support layer 30 is provided in a density in a range of about 3 pounds per cubic foot to about 7 pounds per cubic foot such as about 5 pounds per cubic foot; foams or other materials having different/varying densities may be used for the support layer according to an exemplary embodiment (as indicated schematically in FIGS. 2G and 4A).

As shown schematically according to an exemplary embodiment in FIGS. 2G and 4A, the component shown as panel 10 comprises the layer or laminate shown as cover 50 and a base or substrate 14 attached/formed with a core (e.g. layer, etc.) shown as a foam/plastic material layer 34 and a structure shown as chute 44; as indicated schematically, an airbag module AM (from which a airbag A may deploy) may be installed in the chute. See also FIGS. 1B and 5A-5D. According to an exemplary embodiment, the layer 34 formed between the cover 50 and the substrate 14 ay provide a degree of softness to the panel 10.

According to an exemplary embodiment, the core or layer 34 is made of a polyurethane material (e.g. foam); other suitable foams and/or other materials may be used to create the layer. According to an exemplary embodiment, the material (e.g. plastic, foam, etc.) used to create the core or foam layer 34 has a density in a range of about 6 pounds per cubic foot to about 12 pounds per cubic foot; foams or other plastic materials of varying density may be used according to an exemplary embodiment. According to an exemplary embodiment, the foam layer 34 may be formed with a thickness of approximately 3 millimeters to approximately 15 millimeters; the foam layer 34 may have a thickness of approximately 8 mm.

According to an exemplary embodiment, the panel or trim component for a vehicle interior may be configured to provide an opening (e.g. an opening established at deployment) for deployment of an airbag from a chute through the opening into the vehicle interior. See FIGS. 2G, 4A-4C and 5A-5B. As shown schematically, the component may comprise a substrate 14 providing a structure with a cover 50 comprising a skin layer 18 and a support layer 30 coupled to the skin layer and with a foam layer 34 between the cover and the substrate configured to attach the cover to the substrate). See FIGS. 2A-2B and 2G. According to an exemplary embodiment, the chute 44 may be secured between the foam layer 34 and the substrate 14. See FIGS. 2F and 2G.

According to an exemplary embodiment, the skin layer may comprise a thermoplastic olefin material provided in a generally uniform thickness less than 0.7 mm; the support layer may be provided in a thickness in a range between 1 and 4 mm. As shown schematically according to an exemplary embodiment, the foam layer may be formed from a foam material applied as a liquid configured to attach the cover to the substrate; the foam layer may comprise a foam material provided in a thickness in a range between 3 and 15 mm; the foam material may solidify to attach the cover to the substrate. See FIGS. 2F and 2G. The support layer may have a density between 3 and 7 pounds per cubic foot; the support layer may comprise a foam comprising polypropylene and/or polyethylene. As shown schematically according to an exemplary embodiment, the support layer may be configured to reduce deformation of the cover when force is applied to the cover; deformation may comprise at least one of stretching or elongating. As shown schematically according to an exemplary embodiment, the skin layer may be provided in a uniform manner (e.g. sheet) without a localized area of reduced thickness. See FIGS. 2A-2B, 2F-2G and 3B-3C. The substrate may provide a notch 48 configured to facilitate deployment of the airbag through the opening (e.g. formation of the opening). See FIGS. 2G and 4A-4C.

According to an exemplary embodiment, a trim component for a vehicle interior configured to provide an opening for deployment of an airbag from a chute through the opening may be prepared by a process using a mold (e.g. with mold top section MT and mold bottom section MB). See FIGS. 2C-2F and 3A-3C. As shown schematically according to an exemplary embodiment producing the component may comprise the steps of providing a skin layer 18, applying a support layer 30 to the skin layer to form a cover 50, providing the cover in the mold (MB section), providing the chute in the mold (MT section), providing a substrate 14 in the mold (MT section) and injecting a foam material F between the cover and the substrate (e.g. through port P). See FIGS. 2C-2F and 3A-3C. According to an exemplary embodiment, the foam material F (e.g. formed foam layer or panel 34) may attach the cover 50 and the substrate 14 (e.g. as indicated at surface 28). See FIGS. 2E-2F, 2G and 4A-4C. According to an exemplary embodiment, the process may comprise the step of the foam material (F/34) solidifying to attach the cover 50 to the substrate 14 (see e.g. FIGS. 2E-2F and 2G); the process may comprise the step of securing the chute 44 between the foam material F (e.g. formed foam layer or panel 34) and the substrate 14. See FIGS. 2C-2F and 3B-3C. The cover may comprise a skin layer of a generally uniform thickness of less than 0.7 mm. The skin layer may comprise a thermoplastic olefin material. See FIG. 3C. The support layer may comprise a foam comprising polypropylene and/or polyethylene with a density between 3 and 7 pounds per cubic foot and a thickness in a range between 1 and 4 mm.

As shown schematically according to an exemplary embodiment, a process using a mold for forming a trim component 10 for a vehicle interior configured to provide an opening for deployment of an airbag A from a chute 44 through the opening may comprise the steps of providing a skin layer 18 as a sheet made of a thermoplastic olefin material having a substantially uniform (e.g. substantially constant) thickness less than 0.7 mm, applying a support layer 30 to the skin layer to form a cover 50, providing the cover in the mold (MB section), providing a chute in the mold (MT section), providing a substrate in the mold (MT section), injecting a foam material F between the cover 50 and the substrate 14 (e.g. through port P); and solidifying the foam material to form a foam layer 34 to attach the cover 50 to the substrate 14. See FIGS. 2E-2F, 2G, 3A-3C and 4A-4C. Solidifying the foam material may comprise at least one of (a) hardening or (b) curing. The skin layer may be provided as a substantially uniform layer without a localized area of reduced thickness. See FIGS. 2A-2B and 2G. According to an exemplary embodiment, the process may comprise the step of securing the chute (e.g. entrapping, attaching, etc.) between the foam material and the substrate. See FIGS. 2C, 2G and 3B-3C. According to an exemplary embodiment, applying the support layer to the skin layer to form the cover 50 (with surface 22) may comprise laminating the support layer 30 to the skin layer 18 (e.g. at surface 26). See FIGS. 2A-2B, 2G and 3C. According to an exemplary embodiment, the process may comprise providing a first gap between the cover 50 and the chute 44 and providing a second gap between cover 50 and the substrate 14; the foam material is injected to fill the first gap and to fill the second gap to form the foam layer 34. See FIGS. 2C-2F and 3A-3C.

As shown schematically according to an exemplary embodiment, an airbag A may be deployed from the airbag module AM and through an opening through skin layer 18 (and surface 22) of cover 50 (with support layer 30 and surface 26) and panel/layer 34 (e.g. foam layer with surface 28 and chute 44 (with substrate 14); as indicated schematically the opening is created at deployment of the airbag A from the airbag module AM (e.g. facilitated by a feature in chute/substrate such as notch 48). See e.g. FIGS. 2G, 4A-4C and 5A-5D.

Exemplary Embodiments

As shown schematically in FIG. 1A, a vehicle V includes an interior panel IP. As shown schematically in FIG. 1B, the interior panel 10 is a passenger side interior panel 10. According to an exemplary embodiment, the interior panel 10 could be positioned anywhere within the passenger compartment of the vehicle V associated with an airbag A (shown in FIGS. 4C and 4D). Referring to FIG. 2G, the interior panel 10 includes a rigid substrate 14 providing structural support for the interior panel 10. The interior panel 10 also includes an outer layer or outer skin 18 having a visible first surface or outer surface 22 and a second surface or inner surface 26 that is opposite of the outer surface 22. The outer skin 18 is reinforced by a support layer 30 adjacent the inner surface 26 of the outer skin 18. As shown schematically in FIG. 2G, a foam layer 34 is formed between the support layer 30 and the rigid substrate 14.

According to an exemplary embodiment, the outer skin 18 is made of a thermoplastic olefin (TPO) material; the outer skin 18 has a thickness of approximately 0.5 mm. According to an exemplary embodiment, the thickness of the outer skin 18 is less than about 0.7 mm, and between about 0.3 mm and about 0.7 mm. According to an exemplary embodiment, the interior panel 10 is provided with an outer skin 18 having a thickness that is substantially thinner than that found in state of the art interior panels associated with passenger-side airbags (e.g. interior panel 110 shown in FIG. 6). According to an exemplary embodiment, the outer skin 18 has a sufficiently thin thickness that allows an airbag A to be deployed and burst through the outer skin 18 without having to create or form any pre-weakened areas, scores, or cuts on a portion of the outer skin 18 (see FIG. 2G). The outer surface 22 of the outer skin 18 is visible to passengers within the vehicle V and may be formed with various shapes, patterns and/or textures such that the outer surface 22 may be aesthetically or visually pleasing to the passengers.

According to an exemplary embodiment, the outer skin 18 may be difficult to handle during manufacturing of the interior panel 10 due to the reduced thickness. The support layer 30 is applied to the inner surface 26 of the outer skin 18 to provide additional reinforcement to the outer skin 18 to facilitate the handling of the outer skin 18 during manufacturing of the interior panel 10. According to an exemplary embodiment, the support layer 30 is made of a polypropylene and polyethylene foam. According to an exemplary embodiment, the support layer 30 may be made of or include other various suitable materials. According to an exemplary embodiment, the support layer 30 has a thickness of about 1 mm to about 4 mm. As shown schematically in FIG. 2G, the support layer 30 has a thickness of about 1.5 mm; the foam used to create the support layer 30 has a density of about 5 pounds per cubic foot. According to an exemplary embodiment, the support layer 30 may have a density in a range of about 3 pounds per cubic foot to about 7 pounds per cubic foot; foams or other materials having different densities may be used.

As shown schematically in FIGS. 2A, 2B and 2C-2F, the outer skin 18 with the underlying support layer 30 make up a bi-laminate or multi-layer structure 50; the multi-layer structure 50 is more easily handled and/or manipulated when manufacturing the interior panel 10 according to an exemplary embodiment. According to an exemplary embodiment, the support layer 30 provides additional reinforcement to the outer skin 18; the support layer 30 does not inhibit the deployment of the airbag A; the support layer 30 may help the outer skin 18 to break during an airbag deployment. According to an exemplary embodiment, the support layer 30 is unitized with the outer skin 18; the support layer 30 prevents the outer skin 18 from stretching or elongating during the airbag deployment which may cause the outer skin 18 to break during a deployment sooner compared to the outer skin in a state of the art interior panel (see e.g. interior panel 110 in FIG. 6).

Referring to FIG. 2G, the rigid substrate 14 includes internal sidewalls 38 that define an aperture 42 through which an airbag A (shown in FIGS. 4A to 4C and 5A to 5D) may be deployed. An airbag chute 44 is placed in the aperture 42 and attached to the rigid substrate 14 at the internal sidewalls 38. An airbag module AM (in which the deflated airbag A is contained) is coupled to the airbag chute 44, which is aligned with the aperture 42. The airbag chute 44 is molded or formed with a localized area 48 of reduced thickness (i.e. pre-weakened area 48) such that the airbag A may successfully deploy through the pre-weakened area 48. As shown schematically in FIGS. 5A to 5D, the airbag A is deployed through the interior panel 10 when the vehicle V is impacted according to an exemplary embodiment. Upon impact the airbag A is deployed from the module AM and begins to expand below the interior panel 10, rupturing the airbag chute 44 and causing the foam layer 34 and the structure 50 to bulge outwardly as shown in FIG. 58. As the airbag A continues to expand, the airbag A breaks through the foam layer 34 and the structure 50 (see FIG. 5C) until the airbag A completely inflates within the passenger compartment (FIG. 5D).

According to an exemplary embodiment, the foam layer 34 formed between the support layer 30 and the rigid substrate 14 is provided to add softness to the interior panel 10. According to an exemplary embodiment, the foam layer 34 is made of a polyurethane material. According to an exemplary embodiment, other suitable foams and/or other materials may be used to create the layer 34. According to an exemplary embodiment, the foam used to create the foam layer 34 has a density in a range of about 6 pounds per cubic foot to about 12 pounds per cubic foot; foams or other materials having different densities may be used according to an exemplary embodiment. According to an exemplary embodiment, the foam layer 34 may have a thickness of about 3 millimeters to about 15 millimeters. As shown schematically in FIG. 2G, the foam layer 34 of the interior panel 10 has a thickness of about 8 mm.

According to an exemplary embodiment, to manufacture the interior panel 10 the reinforced multi-layer structure 50 is first created by applying the support layer 30 to the outer skin 18. According to an exemplary embodiment, a laminating process may be used to apply the support layer 30 to the outer skin 18. In a subsequent step, the multi-layer structure 50 is transported to and positioned within a mold. According to an exemplary embodiment, the multi-layer structure 50 is reinforced by the support layer 30; the structure 50 may be transported to the mold without concern of breaking or otherwise damaging the outer skin 18 during transport. According to an exemplary embodiment, the outer skin 18 is substantially thinner than the outer skin 118 of a state of the art interior panel 110 (shown in FIG. 6). According to an exemplary embodiment, the support layer 30 prevents or limits the creation of wrinkles and bunching of the thin outer skin 18 during the foam injection process. The support layer 30 can be considered a manufacturing aid as well as a component that contributes to the overall functionality of the interior panel 10 once manufactured. See generally FIGS. 2A to 2G.

According to an exemplary embodiment, in a subsequent step the multi-layer structure 50 is positioned within the mold with the rigid substrate 14 and the airbag, chute 44 in a spaced relation providing a gap G of about 8 mm between the rigid substrate 14 and the airbag chute 44. According to an exemplary embodiment, in a subsequent step a liquid foam material is injected in the gap and allowed to harden or cure to create the foam layer 34; the liquid foam material is configured to attach the structure 50 to the rigid substrate 14 and chute 44. As shown schematically in FIG. 2G, the airbag chute 44 of the interior panel 10 is secured or captured between the foam layer 34 and the rigid substrate 14. See also FIGS. 4A to 4C. According to an exemplary embodiment, the step of creating the foam layer 34 effectively unitizes the airbag chute 44 to the multi-layer structure 50 and the substrate 14. After the foam layer 34 has cured the interior panel 10 is removed from the mold. The airbag module AM is subsequently attached to the airbag chute 44, completing the assembly of an interior panel 10 (e.g. in the vehicle). According to an exemplary embodiment, no further steps are taken to introduce a localized area of reduced thickness, scoring or otherwise cutting the inner surface 26 of the outer skin 18; the outer skin 18 is sufficiently thin to permit the airbag A to burst through without difficulty.

As shown schematically in FIG. 6, a state of the art vehicle interior panel 110 is associated with a passenger-side airbag. The interior panel 110 includes a rigid substrate 114 and an outer skin 118 having a visible outer surface 122 and an opposite inner surface 126. An airbag chute 144 is attached (e.g. by welding, friction welding, etc.) to a rear or inner surface of the substrate 114 in which an airbag, module 146 is supported. The interior panel 110 also includes a foam layer 134 formed between the outer skin 118 and the rigid substrate 114. The panel 110 also includes a pre-weakened area or score 150 formed through the rigid substrate 114, the foam layer 134 and into the outer skin 118 (e.g. by using a knife or laser, etc.) to provide a localized area of reduced thickness of the outer skin 118. Prior to the score 150 being formed in the outer skin 118, the outer skin 118 has a constant thickness of about 1 mm or greater which is required for the outer skin 118 to be safely transported between molds during the process of manufacturing the interior panel 110; the outer skin 118 is too thick for the airbag to burst through without the score 150.

It is important to note that the construction and arrangement of the elements of the inventive concepts and inventions as described in this application and as shown in the figures above is illustrative only. Although some embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible without materially departing from the novel teachings and advantages of the subject matter recited. Accordingly, all such modifications are intended to be included within the scope of the present inventions. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present inventions.

It is important to note that the apparatus of the present inventions can comprise conventional technology (e.g. as implemented in present configuration) or any other applicable technology (present or future) that has the capability to perform the functions and processes/operations indicated in the FIGURES. All such technology is considered to be within the scope of the present inventions and application. 

1. A trim component for a vehicle interior configured to provide an opening for deployment of an airbag from a chute through the opening comprising: (a) a substrate providing a structure; (b) a cover comprising a skin layer and a support layer coupled to the skin layer; and (c) a core layer configured to attach the cover to the substrate; wherein the skin layer comprises a thermoplastic material provided in a generally uniform thickness less than 0.7 mm.
 2. The trim component of claim 1 wherein the support layer is provided in a thickness in a range between 1 mm and 4 mm.
 3. The trim component of claim 1 wherein the chute is secured between the core layer and the substrate.
 4. The trim component of claim 1 wherein the core layer comprises a foam layer; wherein the foam layer is formed from a foam material applied as a liquid and configured to attach the cover to the substrate; wherein the foam layer comprises a foam material provided in a thickness in a range between 3 and 15 mm.
 5. The trim component of claim 1 wherein the core layer comprises a foam material provided to solidify to attach the cover to the substrate.
 6. The trim component of claim 1 wherein the support layer has a density between 3 and 7 pounds per cubic foot; wherein the support layer is configured to at least partially prevent deformation of the skin layer when force is applied to the cover; wherein deformation comprises at least one of (a) stretching or (b) elongating.
 7. The trim component of claim 1 wherein the skin layer is provided without a localized area of reduced thickness.
 8. The trim component of claim 1 wherein the substrate comprises a notch configured to facilitate deployment of the airbag through the opening by facilitating formation of the opening through the core layer and support layer and skin layer.
 9. A rim component for a vehicle interior configured to provide an opening for deployment of an airbag from a chute through the opening prepared by a process using a mold comprising the steps of: (a) providing a skin layer; (b) applying a support layer to the skin layer to form a cover; (c) providing the cover in the mold; (d) providing the chute in the mold; (e) providing a substrate in the mold; and (f) injecting a thermoplastic material between the cover and the substrate; wherein the thermoplastic material attaches the cover and the substrate.
 10. The trim component of claim 9 wherein the cover comprises a skin layer of a generally uniform thickness of less than 0.7 mm.
 11. The trim component of claim 9 wherein the thermoplastic material comprises a foam material; wherein the process comprises the step of the foam material solidifying to attach the cover to the substrate.
 12. The trim component of claim 9 wherein the process comprises the step of securing the chute between the thermoplastic material and the substrate.
 13. The trim component of claim 9 wherein the skin layer comprises a thermoplastic olefin material.
 14. The trim component of claim 9 wherein the support layer comprises a foam comprising polypropylene and polyethylene with a density between 3 and 7 pounds per cubic foot and a thickness in a range between 1 and 4 mm.
 15. A method using a mold for forming a trim component for a vehicle interior configured to provide an opening for deployment of an airbag from a chute through the opening comprising the steps of: (a) providing a skin layer as a sheet made of a thermoplastic material having a substantially uniform thickness less than 0.7 mm; (b) applying a support layer to the skin layer to form a cover; (c) providing the cover in the mold; (d) providing the chute in the mold; (e) providing a substrate in the mold; (f) injecting a thermoplastic material between the cover and the substrate; and (g) solidifying the thermoplastic material to form a core layer to attach the cover to the substrate.
 16. The method of claim 15 wherein the thermoplastic material comprises a foam material; wherein the core layer comprises a foam layer; wherein solidifying the foam material comprises at least one of (a) hardening or (b) curing.
 17. The method of claim 15 wherein the skin layer is provided as a substantially uniform layer without a localized area of reduced thickness.
 18. The method of claim 15 further comprising the step of securing the chute between the thermoplastic material and the substrate.
 19. The method of claim 15 wherein applying the support layer to the skin layer to form the cover comprises laminating the support layer to the skin layer.
 20. The method of claim 15 further comprising providing a first gap between the cover and the chute and providing a second gap between the cover and the substrate; wherein the thermoplastic material is injected to fill the first gap and to fill the second gap to form the core layer. 